Sorento 2005 3.5L

2005 Kia Sorento LX
2004-06 ENGINES Mechanical - 3.5L V6 - Sorento
2004-06 ENGINES
Mechanical - 3.5L V6 - Sorento
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description Specification Limit
General
Type V-type, DOHC
Number of Cylinders 6
Bore 93 mm (3.661 in.)
Stroke 85.8 mm (3.3779 in.)
Total displacement 3497 cc
Compression ratio 10.0
Firing order 1-2-3-4-5-6
Idle R.P.M 800 ± 100
Ignition timing at idling speed BTDC 10° ± 2°
Valve timing
Intake valve
Opens (BTDC) 16.5°
Closes (ABDC) 55.5°
Exhaust valve
Opens (BBDC) 48.5°
Closes (ATDC) 15.5°
Camshaft
Drive mechanism Cogged type belt
Cam height intake 35.098 - 35.298 mm (1.3818 -
1.3897 in.)
Cam height exhaust 34.81 - 35.01 mm (1.3705 -
1.3783 in.)
Journal diameter 25.951 - 25.970 mm (1.0220 -
1.0224 in.)
Bearing oil clearance 0.05 - 0.09 mm (0.0007 - 0.0024
in.)
End play 0.1 - 0.15 mm (0.0039 - 0.0059
in.)
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.)
Flatness of maunting
Surface
Intake Max. 0.5 mm (0.0197 in.)
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2005 Kia Sorento LX
Exhaust Max. 0.15 mm (0.0059 in.)

Valve guide hole diameter
0.05 (0.002) O.S. 12.05 - 12.068 mm (0.474 - 0.475
in.)
0.25 (0.010) O.S. 12.25 - 12.268 mm (0.482 - 0.483
in.)
0.50 (0.20) O.S. 12.50 - 12.518 mm (0.492 - 0.493
in.)
Intake valve seat ring hole
diameter
0.3 (0.012) O.S. 36.30 - 36.325 mm (1.429 - 1.430
in.)
0.6 (0.024) O.S. 36.60 - 36.625 mm (1.441 - 1.442
in.)
Exhaust valve seat ring hole
diameter
0.3 (0.012) O.S. 33.30 - 33.325 mm (1.311 - 1.312
in.)
0.6 (0.024) O.S. 33.60 - 33.625 mm (1.323 - 1.324
in.)
Valve
Overall length
Intake 106.28 mm (4.184 in.) 105.78 mm (4.165 in.)
Exhaust 105.4 mm (4.150 in.) 104.9 mm (4.130 in.)
Stem diameter
Intake 6.565 - 6.580 mm (0.258 - 0.259
in.)
Exhaust 6.530 - 6.550 mm (0.257 - 0.258
in.)
Face angle 45° - 45.5°
Margin
Intake 1.0 mm (0.0394 in.) 0.5 mm (0.0197 in.)
Exhaust 1.5 mm (0.059 in.) 1.0 mm (0.0394 in.)
Clearance (stem - to - guide)
Intake 0.02 - 0.05 mm (0.0009 - 0.0020 0.1 mm (0.0039 in.)
in.)
Exhaust 0.05 - 0.085 mm (0.0020 - 0.0033 0.15 mm (0.0059 in.)
in.)
Valve spring
Free height 46.4 mm (1.8268 in.) 45.4 mm (1.7874 in.)
Lode 24.0 kgf / 37.9 mm (53 lb /1.492 -
in.)
Out of squareness Max 2° 4°
Valve guide
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2005 Kia Sorento LX
Length
Intake 45.5 mm (1.7913 in.)
Exhaust 50.5 mm (1.9882 in.)
Service oversize 0.05, 0.25, 0.50
Valve seat contact width
Intake 0.9 - 1.3 mm (0.035 - 0.051 in.)
Exhaust 0.9 - 1.3 mm (0.035 - 0.051 in.)
Service oversize 0.30, 0.60
Seat angle
Intake 20°
Exhaust 45°
Piston
Diameter (Standard) 92.97 - 92.98 mm (3.6602 -
3.6606 in.)
Clearance (Piston-to-cylinder) 0.03 - 0.05 mm (0.0012 - 0.0020
in.)
Ring groove width
No. 1 1.53 - 1.55 mm (0.0602 - 0.0610
in.)
No. 2 1.51 - 1.53 mm (0.0594 - 0.0602
in.)
Oil ring 3.010 - 3.030 mm (0.1185 -
0.1193 in.)
Piston for service 0.25 mm (0.010 in.), 0.50 mm
( 0.020 in.)
Oversize
Piston ring
Number of rings per piston 3
Compression ring type 2
Oil ring 1
Compression ring type
No. 1 Barrel type, steel (Inner bevel)
No. 2 Taper type, special cast iron
Oil ring type 3-piece type
Ring end gap
No. 1 0.2 - 0.3 mm (0.0079 - 0.0118 in.) 0.8 mm (0.0315 in)
No. 2 0.45 - 0.60 mm (0.0177 - 0.0236 0.8 mm (0.0315 in)
in.)
Oil ring side rail 0.2 - 0.7 mm (0.0079 - 0.0276 in.) 1.0 mm (0.0394 in)
Ring side clearance
No. 1 0.04 - 0.08 mm (0.0008 - 0.0031 0.1 mm (0.0039 in)
in.)
No. 2 0.02 - 0.06 mm (0.0016 - 0.0024 0.1 mm (0.0039 in)
in.)
2005 Kia Sorento LX
Ring for service 0.25 mm (0.010 in.), 0.50 mm

(0.020 in.)
Over size
Connecting rod
Side clearance (Big end) 0.10 - 0.25 mm (0.0039 - 0.0098
in.)
Bend 0.05 mm or less/100 mm (0.0020
in. or less/3.937 in.)
Twist 0.1 mm or less/100 mm (0.0039
in. or less/3.937 in.)
Bearing
Oil clearance 0.022 - 0.040 mm (0.0009 - 0.1 mm (0.004 in.)
0.0016 in.)
Pin diameter 21.974 - 21.985 mm (0.8651 -
0.8655 in.)
Crankshaft
Journal O.D. 63.982 - 64.00 mm (2.519 -
2.5197 in.)
Pin O.D. 54.982 - 55.00 mm (2.165 -
2.1653 in.)
Out - of - roundness of journal and Max. 0.03 mm (0.0012 in.)
pin
Taper of journal and pin Max. 0.005 mm (0.0002 in.)
End play 0.05 - 0.25 mm (0.002 - 0.0098 0.3 mm (0.012 in.)
in.)
Main bearing
Oil clearance 0.018 - 0.036 mm (0.0007 -
0.0014 in.)
Cylinder block
Cylinder bore 93 mm (3.661 in.)
Flatness of gasket surface Max. 0.05 mm (0.002 in.)
Out - of - roundness and taper Max. 0.02 mm (0.0008 in.) 0.05 mm (0.002 in.)
Oil pump
Side clearance
Body clearance 0.100 - 0.181 mm (0.0039 -
0.0071 in.)
Side clearance 0.040 - 0.095 mm (0.0016 -
0.0037 in.)
Tip clearance 0.06 - 0.018 mm (0.0024 - 0.0071
in.)
Relief spring
Free length 46.3 mm (1.823 in.)
Load 6.9 kg / 39.1 mm (15.2 lb. /1.54
in.)
2005 Kia Sorento LX
Oil filter
Type Cartridge, full flow
Engine oil pressure 80 kPa (0.8 bar, 11.6 psi) at idlae
[Conditions : Oil temperature is 75
to 90°C (167 to 194°F)]
Cooling method Engine coolant cooling, forced
circulation with electric fan
Cooling system
Quantity 11 lit (11.62 U.S.qts., 9.7 lmp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 82°C (179.6°F)
Opening temperature range 80°C - 84°C (176 - 183.2°F)
Wide open temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 86.1 - 124.5 kPa (0.98 - 1.27
kg/cm2 , 13.94 - 18.06 psi)
Main valve closing pressure 83.4 kPa (0.85 kg/cm2 , 12.1 psi)
Vacuum valve opening pressure - 6.86 kPa (- 0.07 kg/cm2 , - 1.00
psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
COOLANT SERVICE STANDARD
Standard Value
Coolant concentration
Tropical area: 40%
Other area: 50%
LUBRICANT
Engine coolant : Ethylene glycol base for aluminum radiator
ENGINE COOLANT TEMPERATURE SENSOR SEALANT
Three bond No. 231 or equivalent LOCTITE 962T or equivalent
2005 Kia Sorento LX
TIGHTENING TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Air Intake Manifold (Upper) Surge Tank-To-Intake Manifold (Lower) Bolt\Nut 11-15 (15-20)
Auto Tensioner Fixing Bolt 15-20 (20-27)
Camshaft Bearing Cap Bolt (1)
Inner Bolt See INCH Lbs.
Outer Bolt 14-15 (19-21)
Camshaft Sprocket Bolt 58-72 (79-98)
Catalytic Converter Nut 22-30 (30-40)
Center Exhaust Pipe Nut 22-30 (30-40)
Connecting Rod Nut
Step 1 26 (35)
Step 2 Plus 92 Degrees
Crankshaft Main Bearing Cap Bolt (1) 51-58 (69-79)
Crankshaft Pulley Bolt 133-140 (180-190)
Cylinder Head Bolts (Cold) (2) 77-85 (105-115)
Delivery Pipe Installation Bolt 7-11 (10-15)
Drive Belt Pulley Bolt 26-41 (35-55)
Drive Belt Tensioner Nut 33-37 (45-50)
Drive Plate & Adapter Plate Bolt 54-57 (73-77)
Engine Coolant Pump-To-Cylinder Head Bolt 13-16 (17-22)
Engine Coolant Temperature Sensor 15-30 (20-40)
Engine Cooling Inlet Fitting Attaching Bolt 13-15 (17-20)
Engine Hanger Bracket Bolt 20-26 (27-35)
Exhaust Manifold-To-Cylinder Head Nut 19-22 (25-30)
Exhaust Manifold-To-Engine 30-33 (40-45)
Front Exhaust Pipe-To-Converter Bolt 30-44 (40-60)
Front Exhaust Pipe-To-Manifold Nut 22-30 (30-40)
Fuel Hose Clamp-To-Rear Cylinder Head 9-11 (12-15)
Generator Inlet Pipe-To-Front Cylinder Head Assembly Bolt 9-11 (12-15)
Generator Mount Bolt (Bracket Side) 15-22 (20-30)
Generator Mount Bracket-To-Engine Bolt 15-22 (20-30)
Generator Mount Nut (Engine Front Case Side) 15-22 (20-30)
Heat Shield-To-Exhaust Manifold Bolts 9-11 (12-15)
Intake Manifold-To-Cylinder Head Nut (3) 15-17 (20-23)
Main Muffler Hanger Support Bracket Bolt 7-11 (10-15)
Oil Filter 8.7-11.6 (11.8-15.7)
Oil Level Gauge Guide-To-Engine Bolt 9-11 (12-15)
Oil Pan Bolt (Upper)
2005 Kia Sorento LX
8x22 mm (4) 14-21 (19-28)

10x38 mm (4) 22-31 (30-42)
152.5 mm 44-62 (5-7)
171.5 mm 44-62 (5-7)
Oil Pan Drain Plug 26-33 (35-45)
Oil Pump Case Bolts 9-11 (12-15)
Oil Pump Cover Screw 5.8-11 (8-15)
Oil Relief Valve Plug 30-37 (40-50)
Oil Screen Bolt 11-16 (15-22)
Oxygen Sensor 30-37 (40-50)
Power Steering Oil Pump Bracket-To-Cylinder Head Bolt 13-19 (17-26)
Power Steering Oil Pump-To-Bracket Bolt 13-19 (17-26)
Starter-To-Engine Bolt 20-25 (27-34)
Starter-To-Engine Nut 15-22 (20-30)
Intake Manifold (Upper) Surge Tank Stay Bolt 11-15 (15-20)
Timing Belt Cover Bolt
M6 Bolt See INCH Lbs.
M8 Bolt 15-20 (20-27)
Timing Belt Idler Pulley Bolt 37-44 (50-60)
Timing Belt Tensioner Arm Fixing Bolt 26-41 (35-55)
Timing Belt Tensioner Pulley Bolt 32-41 (43-55)
Water Outlet Fitting Bolt 13-15 (17-20)
INCH Lbs. (N.m)
Air Cleaner Body Installation Bolt 71-106 (8-12)
Air Cleaner Mounting Bolt 71-106 (8-12)
Camshaft Bearing Cap Bolt (1)
Inner Bolt 89-106 (10-12)
Crankshaft Position Sensor Wheel Screw 35-44 (5-6)
Cylinder Head Cover Bolt (5) 69-87 (7.8-9.8)
Oil Pan Bolt (Lower) (6) 89-106 (10-12)
Oil Pressure Switch 71-106 (8-12)
Oil Seal Case Bolt 89-106 (10-12)
Rear Plate Bolt 89-106 (10-12)
Timing Belt Cover Bolt
M6 Bolt 89-106 (10-12)
Throttle Body-To-Surge Tank Bolt 89-115 (10-13)
Transaxle Mounting Plate Bolt 89-106 (10-12)
(1) Tighten bolts evenly in 3-4 steps to specification.
(2) Tighten in sequence to specification. See Fig. 1.
2005 Kia Sorento LX

Fig. 1: Cylinder Head Bolt Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.
2005 Kia Sorento LX
Fig. 2: Intake Manifold Nut Tightening Sequence

2005 Kia Sorento LX
Fig. 3: Upper Oil Pan Bolt Tightening Sequence

2005 Kia Sorento LX
Fig. 4: Cylinder Head Cover Bolt Tightening Sequence

2005 Kia Sorento LX
Fig. 5: Lower Oil Pan Bolt Tightening Sequence

SPECIAL SERVICE TOOLS
2005 Kia Sorento LX
Fig. 6: Special Service Tools (1 Of 2)

2005 Kia Sorento LX
Fig. 7: Special Service Tools (2 Of 2)

TROUBLESHOOTING
2005 Kia Sorento LX
Fig. 8: Troubleshooting Symptoms Table (1 Of 2)

2005 Kia Sorento LX
Fig. 9: Troubleshooting Symptoms Table (2 Of 2)

CHECKING ENGINE OIL
1. Position a vehicle on a level surface.

2. Turn off the engine.
NOTE: In the case of a vehicle that has not been used for a prolonged period, run
the engine for several minutes. Turn off the engine and wait for 5 minutes
at least, then check the oil level.
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is
found to have fallen to the lower limit (the "L" mark), refill to the "F" mark.
2005 Kia Sorento LX
NOTE: When refilling, use the proper grade of engine oil.
4. Check that the oil is not dirty or mixed with coolant or gasoline, and that it has the proper viscosity.
Fig. 10: Checking Engine Oil Level

SELECTION OF ENGINE OIL
Recommended API classification: SE OR ABOVE [For General]
Recommended API classification: SG OR ABOVE [For North America Europe]
Recommended SAE viscosity grades: See Fig. 11.
2005 Kia Sorento LX
Fig. 11: Recommended SAE Viscosity Grades

NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which:
Satisfy the requirements of the API classification.

Have the proper SAE grade number for expected ambient temperature
range.
Lubricants which do not have both an SAE grade number and an API service classification on the container
should not be used.
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.

2. Turn off the engine.
3. Remove the oil filler cap and oil filter and then drain plug. Drain the engine oil.
2005 Kia Sorento LX
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug: 35-45 Nm (350-450 kg. cm, 25-33 lb. ft)
NOTE: Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill the new engine oil through the oil filler cap.
Drain and Refill
Oil quantity: 4.4 Liters (4.6 U.S. qts., 3.9 Imp. qts.)
NOTE: Do not over fill. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.

7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
REPLACING OIL FILTER
FILTER SELECTION
All KIA Motors Corporation engines are equipped with a high quality, disposable oil filter. This filter is
recommended as a replacement filter for all vehicles. The quality of after market replacement filters varies
considerably.
High quality of replacement filters should be used to assure the most efficient service. Make sure that the rubber
gasket from the old oil filter is completely removed from the contact surface on the engine block before
installing a new filter.
PROCEDURE FOR REPLACING OIL FILTER
1. Use a filter wrench to remove the oil filter.

2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter of the specified torque.
Tightening torque
Oil filter: 11.8-15.7 N.m
(120-160 kg. cm, 8.7-11.6 lb. ft)
4. Start and run the engine and check engine for oil leaks.
2005 Kia Sorento LX
5. After stopping the engine, check the oil level and add oil as necessary.
CHECKING FOR COOLANT LEAK
CAUTION: Radiator coolant may be extremely hot. Do not open the system while
hot, or scalding engine coolant could gush out, causing personal
injury. Allow the vehicle to cool before servicing this system.
When the tester is removed, be careful not to spill any coolant from
it.
Be sure to clean away completely any coolant from the area.
Be careful, when installing and removing the tester and when testing,
not to deform the filler neck of the radiator.
1. Loosen the radiator cap.

2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm2 ) pressure.
Hold for two minutes, then check for leakage from the radiator, hoses or connections.
Fig. 12: Pressure Testing Coolant System For Leaks
2005 Kia Sorento LX
4. If there is leakage, repair or replace with the appropriate part.
RADIATOR CAP PRESSURE TEST
NOTE: Be sure that the cap is clean before testing, since rust or other foreign material
on the cap seal will cause an incorrect reading.
1. Use an adapter to attach the cap to the tester.

2. Increase the pressure until the indicator of the gauge stops moving.
Main value opening pressure:
107.9 +/- 14.7 kPa (1.1 +/- 0.15 Kg/cm2 , 15.64 +/- 2.13 psi)
Main value closing pressure:
83.4 kPa (0.85 Kg/cm2 , 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
2005 Kia Sorento LX
Fig. 13: Performing Radiator Cap Pressure Test

SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.

2. Measure the coolant temperature and calculate the concentration from the relation between the specific
gravity and temperature. Use the following illustration for reference.
2005 Kia Sorento LX
Fig. 14: Testing Specific Gravity

RELATION BETWEEN COOLANT CONCENTRATION & SPECIFIC GRAVITY
CAUTION: If the concentration of the coolant is below 30%, its anti-corrosion

property will be adversely affected.
If the concentration is above 60%, the engine cooling property will
decrease, affecting the engine adversely. For these reasons, be sure
to maintain the concentration level within the specified range.
Do not mix types of antifreeze.
2005 Kia Sorento LX
Fig. 15: Relation Between Coolant Concentration & Specific Gravity Table
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant
temperature of 20°C (68°F)
RECOMMENDED COOLANT
Fig. 16: Recommended Coolant

CHECKING COMPRESSION PRESSURE
1. Before checking the engine compression, check the engine oil level. Also check that the starter motor and
battery are all in normal operating condition.
2. Start the engine and wait until the engine coolant temperature reaches 80-95°C (176-205°F).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Insert the compression gauge into the spark plug hole.
7. Depress the accelerator pedal to open the throttle fully.
8. Crank the engine and read the gauge.
Standard value: 1,275 kPa (13.0 kg/cm2 ), 185 psi)
2005 Kia Sorento LX
Limit: 1,128 kPa (11.5 kg/cm2 , 164 psi)
Fig. 17: Checking Compression Pressure

9. Repeat steps 6 to 8 for all cylinders, making sure that the pressure difference for each of the cylinders is
within the specified limit.
Limit:
Max. 100 kPa (1.0 kg/cm2 , 14 psi) between cylinders
10. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil
through the spark plug hole, and repeat steps 6 to 9.
1. If the addition of oil causes the compression to rise, it is possible that the piston ring is be worn.
2. If the compression remains the same, valve seizure, poor valve seating or a compression leak in the
cylinder head gasket are all possible causes.
Tightening torque
2005 Kia Sorento LX
Spark plug: 20-30 N.m (200-300 kg. cm, 14-22 lb. ft)
TIGHTENING CYLINDER HEAD BOLTS
1. First loosen slightly and then tighten to the specified torque.
Tightening torque
Cylinder head bolts cold [Engine temperature approximately 20°C (68°F)]:
105-115 N.m (1050-1150 kg. cm, 75-82 lb ft.)
Fig. 18: Tightening Cylinder Head Bolts

2. Be sure to follow the specific torque sequence as shown in the illustration.
NOTE: Run the engine to normal operating temperature and let it cool, then re-
2005 Kia Sorento LX
torque the bolts to specifications.
Fig. 19: Cylinder Head Bolt Tightening Sequence

ADJUSTING VALVE CLEARANCE
As the intake and exhaust valves are equipped with hydraulic lash adjusters, there is no need to adjust the valve
clearance. The proper function of the hydraulic lash mechanism may be determined by checking for tappet
noise. When there is a tappet noise or any unusual noise, check the hydraulic lash adjuster by removing and
bleeding or replacing it.
ADJUSTING DRIVE BELT & TENSIONER
1. Hang the belt on the pulley of the tensioner and install the tensioner.
(If the tensioner is already installed, loosen its mounting bolts to allow belt installation.)
Tightening torque
2005 Kia Sorento LX
Tensioner assembly bolt:
45-50 N.m (450-500 kg. cm, 33-36 lb. ft)
Fig. 20: Adjusting Drive Belt & Tensioner

2. Install drive belt.

3. Adjust the drive belt tension to specification by turning the adjusting bolt clockwise or counter clockwise.
2005 Kia Sorento LX
Standard Value
Air Conditioner compressor: 7-10 mm (0.28-0.039 In.)
Alternator: 10-13 mm (0.39-0.51 In.)
Power steering: 8-11 mm (0.31-0.43 In.)
4. When installing the belt on the pulley, make sure it is centered on the pulley.
ENGINE BLOCK
ENGINE BLOCK
COMPONENTS
2005 Kia Sorento LX
2005 Kia Sorento LX
Fig. 21: Crankshaft Main Bearing Cap Torque Specifications

REMOVAL
Remove the CYLINDER HEAD ASSEMBLY, drive plate, transaxle mounting plate, oil pan and oil pump
case.
INSPECTION
1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects.
Replace the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated, in the directions A and B, as
shown in illustration.
Level 1: No. 1 piston ring position at TDC
Level 2: Center of cylinder
Level 3: Bottom of cylinder
2005 Kia Sorento LX
Fig. 22: Measuring Cylinder Bore

3. If the cylinder bores show more than the specified out-of-round or taper, or if the cylinder walls are badly
scuffed or scored, the cylinder block should be re-bored and honed. New oversize pistons and rings
should be installed.
Standard value
Cylinder bore: 93-93.03 mm (3.661-3.6625 In.)
Out-of-round and taper of cylinder bore:
Max. 0.02 mm (0.0008 In.)
4. If a ridge exists at the top of the cylinder, cut it off with a ridge reamer.
5. Oversize pistons are available in two sizes.
Piston service size and mark mm (In.)
0.25 (0.010) O.S: 0.25
0.50 (0.020) O.S: 0.50
6. To re-bore the cylinder bore to the oversize, maintain the specified clearance between the oversize piston
and the bore and make sure that all used pistons are the same oversize. The standard measurement of the
piston outside diameter is taken at a level of 10 mm (0.39 In.) above the bottom of the piston skirt and
across the thrust faces.
Piston-to-cylinder clearance:
0.03-0.05 mm (0.0012-0.0020 In.)
2005 Kia Sorento LX
Fig. 23: Measuring Piston

7. Check for damage or cracks in the cylinders.

8. Check the top surface of the cylinder block for flatness. If the top surface exceeds the limit, grind to the
minimum limit or replace.
Standard value
Flatness of gasket surface:
Max. 0.03 mm (0.0012 In.)
Service limit
Flatness of gasket surface: 0.05 mm (0.0020 In.)
CAUTION: When the cylinder head is assembled, grinding less than 0.2 mm
(0.008 In.) is permissible.
2005 Kia Sorento LX
Fig. 24: Checking Cylinder Block For Flatness

BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
Fig. 25: Oversize Piston Identification
2005 Kia Sorento LX
NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D. + 0.03 to 0.05 mm (0.0012 to 0.002 In.) (clearance between piston and
cylinder) -0.01 mm (0.0004 In.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard: 0.03-0.05 mm (0.0012- 0.0020 In.)
NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.
ENGINE MOUNTS
COMPONENTS
2005 Kia Sorento LX
Fig. 26: Identifying Engine Mounts & Torque Specifications

MAIN MOVING SYSTEM

CAMSHAFT
COMPONENTS
2005 Kia Sorento LX
Fig. 27: Identifying Camshaft System Components & Torque Specifications

DISASSEMBLY
1. Remove intake manifold.

2. Disconnect the breather hose and the engine harness.
2005 Kia Sorento LX
3. Remove the power steering pulley, air conditioner pulley, crankshaft pulley, idler pulley and tensioner
pulley.
4. Remove the timing belt cover.
5. Loosen the auto tensioner.
6. Remove the timing belt from the camshaft sprocket.
7. Remove the spark plug cables.
8. Loosen the cylinder head (valve) cover bolts and then remove it.
9. Remove the camshaft sprockets.
10. Remove the camshaft bearing caps.
11. Remove the camshafts.
INSPECTION
CAMSHAFTS
1. Check the camshaft journals for wear. If the journals are badly worn out, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn out, replace the camshaft.
Cam height
[Standard]
Intake: 35.098-35.298 mm (1.3818-1.3897 In.)
Exhaust: 34.81-35.01 mm (1.3705-1.3783 In.)
2005 Kia Sorento LX
Fig. 28: Measuring Cam Lobes

3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head
assembly or camshaft bearing cap, as necessary.
Camshaft end play: 0.1-0.15 mm (0.0039-0.0059 In.)
OIL SEAL (CAMSHAFT FRONT)
1. Check the lips for wear. If lip threads are worn out, replace the oil seal with new one.
2. Check a contact surface of oil seal lip on camshaft. If there stratified wear, replace the camshaft.
HLA (HYDRAULIC LASH ADJUSTER)
With the HLA filled with engine oil, hold A and press B by hand, as shown in illustration. If B moves, replace
the HLA.
2005 Kia Sorento LX
Fig. 29: Inspecting Hydraulic Lash Adjusters

2005 Kia Sorento LX
Fig. 30: Hydraulic Lash Adjuster Symptom Table

AUTO-LASH ADJUSTER
1. Check auto-lash adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and push the auto lash adjuster check ball down very lightly.
2. While lightly holding the check ball down, move the rocker arm up and down to check for free play. If
there is no play, replace the auto-lash adjuster.
2005 Kia Sorento LX
Fig. 31: Inspecting Auto-Lash Adjusters

REASSEMBLY
CAMSHAFT & BEARING CAP
1. Rotate the crankshaft and ensure No. 1 cylinder is in TDC (Compression stroke).
2. Ensure position of the rocker arm is installed exactly on the lash adjuster and valve.
3. Install the camshaft dowel pin as shown in illustration.
2005 Kia Sorento LX
Fig. 32: Camshaft Installation Positions At TDC

4. The left and right banks of the camshafts are different and you should be careful not to confuse them.
2005 Kia Sorento LX
Identification signal
Left bank
Intake (IN) : I
Exhaust (Ex): E
Right bank
Intake (IN) : J
Exhaust (Ex): H
Fig. 33: Identifying Location Of Camshaft Identification Marks

5. Confirm the identification mark and the number. Bearing caps of No.3, No.4, and No.5 have the front
mark and arrange the front mark upon the cylinder head while installing the bearing caps.
Identification mark
Intake : I
Exhaust : E
6. Tighten the bearing cap by 2 or 3 steps
Tightening Torque
Outer (See Fig. 34 for * identification.) 16 EA: 18.6-20.6 N.m (190-210 kg. cm, 13.7-15.2 lb. ft)
2005 Kia Sorento LX
Inner 24 EA: 9.8-11.8 N.m (100-120 kg. cm, 7.2-8.7 lb. ft)
Fig. 34: Identifying Outer Camshaft Bearing Caps

7. Install the cylinder head cover.

1. Install the gasket to the cylinder head cover correctly.
2. Clean sealing surface on camshaft cap.
NOTE: Clean sealing surface using a plastic scraper, to prevent oil leak.
3. Apply sealant to the sealing surface on cylinder head cover and camshaft cap.
2005 Kia Sorento LX
Fig. 35: Apply Sealant To The Sealing Surface Of Camshaft Cap

4. Install the cylinder head cover to the cylinder head.
NOTE: Be careful of gasket escapement when installing the cylinder head

cover. You must use the washers when installing the cylinder head
cover bolts.
2005 Kia Sorento LX
Fig. 36: Cylinder Head Cover Bolt Tightening Sequence

CONNECTING ROD
COMPONENTS
2005 Kia Sorento LX
Fig. 37: Identifying Connecting Rod Components & Torque Specifications

DISASSEMBLY
2005 Kia Sorento LX
CONNECTING ROD CAP
CAUTION: Keep the bearings in order with their corresponding connecting rods
(according to cylinder numbers) for proper reassembly.
1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing mark for
reassembly.
2. Push each piston connecting rod assembly toward the top of the cylinder.
INSPECTION
PISTONS & PISTON PINS
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the
piston requires replacement, its rings should also be replaced.
3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective.
The piston pin must be pressed smoothly by hand into the pin hole (at room temperature).
PISTON RINGS
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring
in the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the
piston and rings together. If it is less than the service limit, replace only the piston rings.
Piston ring side clearance
No.1 : 0.04-0.08 mm (0.0016-0.0031 In.)
No.2 : 0.02-0.06 mm (0.0008-0.0024 In.)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring.
Piston ring end gap
[Standard dimensions]
No.1 : 0.2-0.3 mm (0.0079-0.00118 In.)
No.2 : 0.45-0.60 mm (0.0177-0.0236 In.)
Oil ring side rail : 0.2-0.7 mm (0.0079-0.0276)
When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the lower
2005 Kia Sorento LX
part of cylinder that is less worn out.
PISTON RING SERVICE SIZE & MARK
NOTE: The mark can be found on the upper side of the ring next to the end.
Fig. 38: Piston Ring Service Size & Mark

CONNECTING RODS
1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at
disassembly, match. When a new connecting rod is installed, make sure that the notches holding the
bearings in place are on the same side.
2. Replace the connecting rod if it is damaged at either end of the thrust faces. If it has a stratified wear, or if
the surface of the inside diameter of the small end is severely rough, replace the rod.
2005 Kia Sorento LX
Fig. 39: Identifying Connecting Rod Notches

REASSEMBLY
1. Install the expander.
2005 Kia Sorento LX
Fig. 40: Identifying Oil Ring Components

2005 Kia Sorento LX
Fig. 41: Aligning Oil Ring Spacer & Side Rail Gaps
2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring
groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove
(as illustrated).
CAUTION: Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure described in Step 2.
Fig. 42: Proper Technique To Install Side Rails

4. Apply engine oil around the piston and piston grooves.

5. Using a piston ring expander, install the No.2 piston ring.
6. Install the No. 1 piston ring.
2005 Kia Sorento LX
Fig. 43: Identifying No. 1 & 2 Piston Rings

7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the
gaps are not positioned in the thrust and pin directions.
8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
2005 Kia Sorento LX
Fig. 44: Aligning Piston Rings Gaps

9. Install the upper connecting rod bearings in the connecting rod.

10. Install the lower connecting rod bearing in the connecting rod bearing caps.
11. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod
are directed toward the front of the engine.
12. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap
at disassembly match.
13. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on
the same side.
14. When assembling, bolts should be fastened using the plastic angle technique as follows.
1. Apply oil to the threads and matching areas.
2. Tighten the connecting rod bolt.
Tightening torque
Connecting rod bolt:
35 N.m + 92° (350 kg. cm + 92°, 26 lb. ft + 92°)
2005 Kia Sorento LX
CAUTION: After removing the connecting rod bolt, do not use it again.
When using a new bolt, do not tighten the bolt more than 3
times.
15. Check the connecting rod side clearance.
Connecting rod side clearance
Standard: 0.10-0.25 mm (0.0039-0.0098 In.)
Limit : 0.4 mm (0.0157 In.)
Fig. 45: Measuring Connecting Rod Side Clearance

REPLACEMENT
CONNECTING ROD BEARING
1. Check the connecting rod big end bore size code.
2005 Kia Sorento LX
NOTE: Record the connecting rod big end bore size code letters on connecting
rod cap as shown in illustration.
Fig. 46: Identifying Location Of Connecting Rod Big End Bore Size Code
Fig. 47: Connecting Rod Big End Diameter Table

2. Check the crankshaft pin journal size code.
2005 Kia Sorento LX
NOTE: Record the pin journal size code letters on the crankshaft balance weight.
Reading order is from left to right as shown in illustration, with No. 1 pin
journal size code shown first.
Fig. 48: Identifying Location Of Crankshaft Pin Journal Size Code

Fig. 49: Crankshaft Pin Journal Diameter Table
2005 Kia Sorento LX
3. Choose proper connecting rod bearing as shown in illustration.
Fig. 50: Connecting Rod Bearing Selection Table

Connecting rod bearing oil clearance:
0.026-0.044 mm (0.0010-0.0017 in)
Fig. 51: Connecting Rod Bearing Thickness Table (Reference Data)

2005 Kia Sorento LX
CRANKSHAFT
COMPONENTS
Fig. 52: Identifying Crankshaft Components & Torque Specifications

DISASSEMBLY
2005 Kia Sorento LX
1. Remove the CYLINDER HEAD ASSEMBLY and oil pan.

2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
NOTE: Mark the main bearing caps to be able to reassemble in the original
position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the
cap number.
INSPECTION
CRANKSHAFT
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective parts.
2. Inspect the crankshaft journal and pin for out-of-round and taper.
Standard value
Crankshaft journal O.D.:
63.982-64.00 mm (2.519-2.5197 In.)
Crankshaft pin O.D.:
54.982-55.00 mm (2.165-2.1653 In.)
2005 Kia Sorento LX
Fig. 53: Measuring Crankshaft Outside Dimensions (O.D.)

MAIN BEARINGS & CONNECTING ROD BEARINGS
Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace any defective
bearings.
MEASURING OIL CLEARANCE
Check for oil clearance by measuring the outside diameter of the crankshaft journal and the inside diameter of
the bearing. The clearance can be obtained by calculating the difference between the measured outside
diameters.
Standard value
Oil clearance
Crankshaft main bearing:
2005 Kia Sorento LX
0.018-0.036 mm (0.0007-0.0014 In.)
Connecting rod bearing:
0.022-0.048 mm (0.0009-0.002 In.)
Fig. 54: Measuring Crankshaft Journal Bearings

PLASTIGAGE METHOD
Plastigage may be used to measure the clearance.
1. Remove oil, grease and any other dirt from the bearings and journals.
2. Cut the plastigage the same length as the width of the bearing and place it in parallel with the journal,
avoiding the oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation,
do not turn the crankshaft. Remove the caps. Measure the width of the plastigage at the widest part by
using the scale printed on the gauge package.
If the clearance exceeds the service limit, the bearing should be replaced or an undersize bearing should
be used. When installing a new crankshaft, be sure to use standard size bearings.
If the standard clearance can not be obtained even after replacing the bearing, the journal and pin should
be ground to the undersize and a bearing of the corresponding size should be installed.
2005 Kia Sorento LX
Fig. 55: Using Plastigage

OIL SEAL
Check the front and rear oil seals for damage or worn surfaces. Replace any seal that is defective.
DRIVE PLATE (A/T)
Replace distorted, damaged, or cracked drive plates.
REASSEMBLY
MAIN BEARING
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Install the crankshaft. Apply engine oil to journal and pin.
4. Install the bearing caps with the arrow mark directed toward the front of the engine. Cap number must be
correct.
5. Tighten the cap bolts to the specified torque.
2005 Kia Sorento LX
Tightening torque
Main bearing cap bolts:
68.6-78.5 N.m (700-800 kg. cm, 50.6-57.9 lb. ft)
Fig. 56: Identifying Grooved & Grooveless Bearings

6. Cap bolts should be tightened evenly in stages 4 to 5 increments before they are tightened to the specified
torque.
7. Make certain that crankshaft turns freely and check the end play of the crankshaft.
Crankshaft end play
Standard: 0.070-0.250 mm (0.0028-0.0098 In.)
Limit: 0.35 mm (0.014 In.)
2005 Kia Sorento LX
Fig. 57: Measuring Crankshaft End Play

8. Using special tool (09231-33000), install the rear oil seal in oil seal case.
9. Apply sealant to the area shown in the illustration. Install the oil seal case in the cylinder block.
Tightening torque
Oil seal case bolt:
10-12 N.m (100-120 kg. cm, 7-9 lb. ft)
2005 Kia Sorento LX
Fig. 58: Using Special Tool, Install Rear Oil Seal In Oil Seal Case
2005 Kia Sorento LX
Fig. 59: Apply Sealant To The Oil Seal Case

10. Tighten the rear plate to the specified torque.
Tightening torque
Rear plate: 10-12 N.m (100-120 kg. cm, 7-9 lb. ft)
11. Tighten the drive plate and the adapter plate (A/T).
Tightening torque
Drive plate and adapter plate bolt:
73-77 N.m (730-770 kg. cm, 53-56 lb. ft)
2005 Kia Sorento LX
Fig. 60: Identifying Drive & Adapter Plate Components

REPLACEMENT
2005 Kia Sorento LX
CRANKSHAFT MAIN BEARING
1. Check the cylinder block main bearing bore size code.
NOTE: Record the cylinder block main bearing bore size code letters on cylinder
block as shown in illustration.
Reading order is from left to right with front main bearing bore size code
shown first.
Fig. 61: Identifying Location Of Cylinder Block Main Bearing Bore Size Code
2005 Kia Sorento LX
Fig. 62: Cylinder Block Main Bearing Bore Diameter Table

2. Check the crankshaft main journal size code.
NOTE: Record the main journal size code letters on the crankshaft balance
weight.
Reading order is from left to right as shown in illustration, with No. 1 main
journal size code shown first.
Fig. 63: Identifying Location Of Main Journal Size Code

2005 Kia Sorento LX
Fig. 64: Crankshaft Main Journal Diameter Table

3. Choose proper main journal bearing as shown in illustration.
Fig. 65: Main Journal Bearing Selection Table

Main journal bearing oil clearance:
0.022-0.040 mm (0.0009-0.0016 in)
2005 Kia Sorento LX
Fig. 66: Main Journal Bearing Thickness Table (Reference Data)

COOLING SYSTEM
ENGINE COOLANT HOSE/PIPES
COMPONENTS
2005 Kia Sorento LX
Fig. 67: Identifying Engine Coolant Pipe Components

INSPECTION
Check the engine coolant pipe and hose for cracks, damage and restrictions. Replace if necessary.
REASSEMBLY
Fit the O-ring in the groove of the engine coolant inlet pipe end. Wet the periphery of the O-ring with water and
insert the engine coolant inlet pipe.
NOTE:
2005 Kia Sorento LX
Do not apply oil or grease to the engine coolant pipe O-ring.

Keep the engine coolant pipe connections free of sand, dust, etc.
Insert the engine coolant pipe into the end of the engine coolant pump
inlet.
Whenever installing the engine coolant inlet pipe, always replace the O-
ring with a new one.
COOLANT TEMPERATURE SENSOR
REMOVAL
1. Drain the engine coolant.

2. Disconnect the engine coolant temperature sensor connector after disconnecting the ground cable of the
battery.
3. Remove the engine coolant temperature sensor.
Fig. 68: Identifying Engine Coolant Temperature Sensor

2005 Kia Sorento LX
INSTALLATION
1. Apply sealant to the sensor's threads. Tighten it to the specified torque.
Recommended sealant:
Three bond No. 2310 or LOCTITE 962T
Tightening torque
The coolant sensor:
20-40 N.m (200-400 kg. cm, 14-29 lb. ft)
2. Connect the coolant temperature sensor to the harness.

3. Connect the ground cable of battery.
4. Refill the coolant.
SCHEMATIC DIAGRAM
Fig. 69: Inlet Control Schematic

2005 Kia Sorento LX
Fig. 70: Identifying Coolant Flow Chart

2005 Kia Sorento LX
ENGINE COOLANT PUMP
COMPONENTS
Fig. 71: Identifying Engine Coolant Pump Components & Torque Specifications
REMOVAL
1. Using the drain plug, drain the coolant.

2. Remove the drive belt and the engine coolant pump pulley.
3. Remove the timing belt cover, the auto tensioner and idler pulley.
4. Remove the water outlet fitting, the thermostat case and the water pump fitting.
2005 Kia Sorento LX
5. Remove the engine coolant pump mounting bolts.

6. Remove the engine coolant pump assembly from the cylinder block.
Fig. 72: Identifying Engine Coolant Pump Mounting Bolts

INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation and replace the pump assembly if
necessary.
3. Check the seal for leaks and replace the pump assembly if necessary.
INSTALLATION
2005 Kia Sorento LX
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new engine coolant pump gasket and pump assembly. Tighten the bolts to the specified torque.
Tightening torque
Engine coolant pump bolt:
Head mark "7": 17-22 N.m (170-220 kg. cm, 12-16 lb. ft)
Fig. 73: Identifying Water Pump Mounting Bolts

3. Install the water pump fitting, the thermostat case and the water outlet fitting.
2005 Kia Sorento LX
Fig. 74: Ensure Water Pipe O-Ring Engagement

4. Install the auto tensioner and timing belt. Adjust the timing belt tension, then install the timing belt cover.
5. Install the driver belt, coolant pump pulley and then adjust the auto tensioner.
7. Run the engine and check for leaks.
RADIATOR
2005 Kia Sorento LX
COMPONENTS
Fig. 75: Identifying Radiator & Fan Components

REMOVAL
1. Disconnect the ground cable from the battery terminal.

2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after marking the radiator hose and the hose
clamp for reassembly reference.
CAUTION: Cover or plug the hose and inlets of the radiator so that dust and
other foreign material etc. cannot enter after the hose is
disconnected from the radiator.
5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle. Plug
2005 Kia Sorento LX
hoses and inlets to prevent fluid leakage.

6. Remove the air conditioner condenser fixing bolts and radiator bracket fixing nuts.
Fig. 76: Identifying Condenser Mounting Bolts

7. Remove the radiator and the fan motor.

8. Remove the radiator fan motor and condenser fan motor from the radiator.
INSPECTION
1. Check for foreign material between the radiator fins.

2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reservoir tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration (only A/T).
INSTALLATION
1. To install, reverse removal procedure.

2. Fill the radiator and reservoir tank with a clean coolant mixture.
2005 Kia Sorento LX
3. Run the engine until the coolant warms up enough so that the thermostat value opens and then turn off the
engine.
4. Remove the radiator cap and pour the coolant up to the filler neck of the radiator. Fill the reservoir tank to
the upper level.
5. Check that there are no leaks from the radiator, hoses or connections.
6. Check auto transmission fluid level and fill to appropriate level, as necessary.
RADIATOR FAN MOTOR
COMPONENTS
Fig. 77: Identifying Radiator Fan Motor Components

REMOVAL
1. Disconnect the ground cable from the battery cable.

2. Disconnect the connectors from the fan motor.
3. Remove the radiator fan assembly mounting bolts.
2005 Kia Sorento LX
Fig. 78: Identifying Radiator Fan Assembly Mounting Bolts

4. Remove the radiator fan assembly from the radiator.
2005 Kia Sorento LX
5. Remove the fan mounting clip and detach the fan from the fan motor.
INSPECTION
RADIATOR FAN MOTOR & CONDENSER FAN MOTOR
1. Check that the radiator fan rotates when battery voltage is applied between the terminals.
2. Check that there are no abnormal noises while the motor is running.
Fig. 79: Testing Fan Motors

RADIATOR FAN MOTOR RELAY
1. Remove the radiator fan motor relay from the relay box in the engine room.
2. Check continuity with an ohmmeter.
2005 Kia Sorento LX
Fig. 80: Fan Relay Terminal Continuity Specifications Table

3. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.
Fig. 81: Identifying Fan Relay Terminals

4. If there is no continuity, replace fan motor relay.
RADIATOR CAP
COMPONENTS
2005 Kia Sorento LX
Fig. 82: Identifying Radiator Cap Flow & Pressure Specifications

INSPECTION
1. Check the radiator cap for damage, cracks or weakening.

2. Connect the tester to the radiator cap.
3. Increase the pressure until the indicator of the gauge stops moving.
4. Replace the radiator cap if the reading does not hold steady for about 10 seconds.
2005 Kia Sorento LX
Fig. 83: Pressure Testing Radiator Cap

THERMOSTAT
REMOVAL
1. Drain the coolant to thermostat level or below.

2. Remove the inlet fitting and gasket.
3. Remove the thermostat.
INSPECTION
1. Heat the thermostat as shown in the illustration.

2. Check that the valve operates properly.
3. Verify the temperature at which the valve begins to open.
2005 Kia Sorento LX
Valve opening temperature: 80-84°C (176-183.2°F)
Full opening temperature: 95°C (203°C)
Fig. 84: Heating Thermostat For Testing

INSTALLATION
1. Check that the flange of the thermostat is correctly placed in the socket of the thermostat housing.
2005 Kia Sorento LX
Fig. 85: Identifying Installation Position Of Thermostat

2. Install the inlet fitting.
Tightening torque
Engine coolant inlet fitting bolt:
17-20 N.m (170-200 kg. cm, 12-14 lb. ft)
LUBRICATION SYSTEM
OIL PUMP
COMPONENTS
2005 Kia Sorento LX
Fig. 86: Identifying Lubrication System Components & Torque Specifications

DISASSEMBLY
1. Remove the oil pressure switch, using 24 mm deep socket.
NOTE: Since a sealant is used on the threaded area, be careful not to damage the
2005 Kia Sorento LX
oil pressure switch.
2. Remove the oil filter and the oil pan.

3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove the oil filter bracket and gasket.
5. Remove the oil relief value plug from the oil pump case.
6. Remove the oil pump case.
INSPECTION
OIL PUMP
1. Visually check the parts of the oil pump case for cracks and damage.
2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge.
Oil pump side clearance
Standard value
Body clearance: 0.100-0.181 mm (0.0039-0.0071 In.)
Side clearance: 0.040-0.095 mm (0.0016-0.0037 In.)
Oil pump Tip clearance
0.06-0.18 mm (0.0024-0.0071 In.)
2005 Kia Sorento LX
Fig. 87: Measuring Oil Pump Clearances

RELIEF PLUNGER & SPRING
1. Check the relief plunger for smooth operation.

2. Check the relief spring for deformation or breaks.
OIL FILTER BRACKET
1. Make sure that there is no damage on the oil filter mating surface.
2. Check the oil filter bracket for oil leaks or cracks.
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity,
replace the oil pressure switch.
2. Check the continuity between the terminal and the body when a fine wire is pushed in through oil hole. If
2005 Kia Sorento LX
there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (0.5 kg/cm2 , 7 psi) vacuum is applied through the oil hole, the
switch is operating properly.
4. Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
Operation Pressure
Oil Pressure switch:
19.6-39.2 kPa (0.2-0.4 kg/cm2 , 2.8-5.7 psi) or more
REASSEMBLY
1. Install the oil pump case with the gasket.
Tightening torque
Oil pump case bolt:
12-15 N.m (120-150 kg. cm, 9-11 lb. ft)
Oil pump cover screw:
8-12 N.m (80-120 kg. cm, 6-9 lb. ft)
2. Install the oil seal into the oil pump case as tightly as possible, using the special tool (09214-33000).
2005 Kia Sorento LX
Fig. 88: Using The Special Tool, Install The Oil Seal Into The Oil Pump Case
3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque.
Tightening torque
Oil relief valve plug:
40-50 N.m (400-500 kg. cm, 29-36 lb. ft)
4. Install the oil screen and a new gasket.
Tightening torque
Oil screen bolt:
15-22 N.m (150-220 kg. cm, 11-15 lb. ft)
5. Clean the gasket surfaces of the cylinder block and the oil pan.
6. Apply sealant to the groove of the oil pan flange.
NOTE: Make the first cut approximately 4 mm from the end of the nozzle
furnished with the sealant. After application of the sealant, do not
2005 Kia Sorento LX
exceed 15 minutes before installing the oil pan.

Make sure that the sealant doesn't enter the inside of the oil pan.
7. Tighten the oil pan bolts as shown in the illustration.
Tightening torque
9.8-11.8 N.m (100-120 kg. cm, 7.2-8.7 lb. ft)
4.9-6.9 N.m (50-70 kg. cm, 3.6-5.1 lb. ft) (No. 15-16)
Fig. 89: Identifying Upper Oil Pan Bolt Tightening Sequence

8. Tighten the transmission mounting bolts from oil pan.
Tightening torque (mounting bolts)
29.4-41.2 N.m (300-420 kg. cm, 21.7-30.4 lb. ft)
2005 Kia Sorento LX
Fig. 90: Identifying Transmission Mounting Bolts

9. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant: Three bond No. 1104E or equivalent
NOTE: Do not torque the oil pressure switch too much.
Tightening torque
Oil pressure switch:
8-12 N.m (80-120 kg. cm, 6-9 lb. ft)
10. Tighten the lower oil pan bolts as shown in illustration.
Tightening torque
9.8-11.8 N.m (100-120 kg. cm, 7.2-8.7 lb. ft)
2005 Kia Sorento LX
Fig. 91: Identifying Lower Oil Pan Bolt Tightening Sequence

INTAKE & EXHAUST SYSTEM

EXHAUST MANIFOLD
COMPONENTS
2005 Kia Sorento LX
Fig. 92: Identifying Exhaust Manifold Components & Torque Specifications

REMOVAL
1. Remove the heat protector.

2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket.
INSPECTION
2005 Kia Sorento LX
1. Check for damage or cracks.

2. Using a straight edge and feeler gauge, check for distortion on the exhaust manifold.
Standard value: 0.15 mm (0.006 In.) or less
Service limit: 0.3 mm (0.012 In.) or less
Fig. 93: Inspecting Exhaust Manifold For Distortion

INSTALLATION
1. Install the exhaust manifold with gasket.
Tightening torque
26.5-32.4 N.m (270-330 kg. cm, 19.5-23.9 lb. ft)
NOTE: Do not re-use an exhaust manifold gasket.
2. Install the heat protector.
Tightening torque
11.8-14.7 N.m (120-150 kg. cm, 8.7-10.8 lb. ft)
INTAKE MANIFOLD
COMPONENTS
2005 Kia Sorento LX
Fig. 94: Identifying Intake Manifold Components

REMOVAL
2005 Kia Sorento LX
1. Remove the air intake hose connected to the throttle body.

2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose and throttle body.
4. Remove the P.C.V. hose and brake booster vacuum hoses.
5. Disconnect the vacuum hose connections.
6. Remove the surge tank stay.
Fig. 95: Identifying Surge Tank Stays (Engine Left Rear View)
2005 Kia Sorento LX
Fig. 96: Identifying Surge Tank Stays (Engine Right Front View)
7. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.
8. Disconnect the connector from high pressure hose.
2005 Kia Sorento LX
Fig. 97: Identifying Connector From High Pressure Hose

9. Remove bolts and the surge tank and gasket.

10. Disconnect the fuel injector harness connector.
2005 Kia Sorento LX
Fig. 98: Disconnect The Fuel Injector Harness Connector

11. Remove the delivery pipe with the fuel injector and the pressure regulator.
NOTE: When the delivery pipe is removed, be careful not to drop an injector.
2005 Kia Sorento LX
Fig. 99: Remove Delivery Pipe

12. Disconnect the wiring harness of the coolant sensor assembly.

13. Remove the bolts and intake manifold.
INSPECTION
SURGE TANK & INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cracking or restriction of the vacuum outlet port,
water or gas passages.
2. Check for distortion on the surface using a straight edge and feeler gauge.
Standard value: 0.15 mm (0.006 In.) or less
Service limit: 0.2 mm (0.0078 In.)
2005 Kia Sorento LX
Fig. 100: Using A Straight Edge & Feeler Gauge, Check Surge Tank & Intake Manifold For Distortion
INSTALLATION
Install the intake manifold and delivery pipe reversing the order of the removal procedure.
Tightening torque
Intake manifold:
19.6-22.6 N.m (200-230 kg. cm, 14.5-16.6 lb. ft)
Surge tank stay:
15-20 N.m (150-200 kg. cm, 11-14 lb. ft)
MUFFLER
COMPONENTS
2005 Kia Sorento LX
Fig. 101: Identifying Exhaust Muffler Components & Torque Specifications

AIR CLEANER
COMPONENTS
2005 Kia Sorento LX
Fig. 102: Identifying Air Cleaner Components

INSPECTION
1. Check the air intake hose and air cleaner cover for damage.
2. Check the air duct for damage.
3. Check the air cleaner element for restriction, contamination or damage.
4. If the element is slightly restricted, remove dust and debris by blowing compressed air from the inside of
the element. Replace the element if it cannot be cleaned.
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD
COMPONENTS
2005 Kia Sorento LX
Fig. 103: Identifying Cylinder Head Components & Torque Specifications

DISASSEMBLY
1. Drain the coolant and disconnect the upper radiator hose.

2. Remove the breather hose and air-intake hose.
3. Remove the vacuum hose, fuel hose and coolant hose.
4. Remove the intake manifold.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
2005 Kia Sorento LX
7. Remove the upper and lower timing belt cover.

8. Remove the timing belt and camshaft sprockets. See TIMING BELT.
Fig. 104: Identifying Timing Belt & Camshaft Sprockets

9. Remove the heat protector and exhaust manifold assembly.

10. Remove the coolant pump pulley and head cover.
11. Remove the intake and exhaust camshaft.
12. Remove the cylinder head assembly. The cylinder head bolts should be removed using the 12 mm socket,
in two or three steps following the sequence as shown in illustration.
2005 Kia Sorento LX
Fig. 105: Identifying Cylinder Head Bolt Removal Sequence

13. Clean the gasket pieces from the cylinder block top surface and cylinder head bottom surface.
NOTE: Make sure that fragments from the gasket do not fall in the engine.
RETAINER LOCK
1. Compress the valve spring using special tool (09222-28000, 09222-28100).

2. Remove the retainer lock.
2005 Kia Sorento LX
Fig. 106: Using Special Tool, Compress Spring & Remove Retainer Locks
INSPECTION
CYLINDER HEAD
1. Remove scale, sealing compound and carbon deposits. After cleaning oil passages, apply compressed air
to make certain that the passages are not clogged.
2. Visually check the cylinder head for cracks, damage or water leakage.
3. Check the cylinder head surface for flatness with a straight edge and feeler gauge as shown in the
illustration.
Cylinder head flatness:
Standard dimensions: Max. 0.03 mm (0.0059 In.)
Service limit: 0.05 mm (0.0020 In.)
2005 Kia Sorento LX
Fig. 107: Checking Cylinder Head Flatness

VALVE GUIDES
Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with
a new oversize guide.
Valve stem-to-guide clearance
Standard value
Intake: 0.02-0.05 mm (0.0009-0.0020 In.)
Exhaust: 0.050-0.085 mm (0.0020-0.0033 In.)
2005 Kia Sorento LX
Fig. 108: Checking Valve Stem-To-Guide Clearance

VALVE
1. Replace the valve if its stem is bent, worn or damaged. Also replace it if the stem end (the surface
contacting the hydraulic-lash adjuster) is hollowed out.
2. Check the valve face contact area, and recondition or replace as necessary.
3. Replace the valve if the width of the margin (thickness of the valve head) is less than the minimum
specified.
Valve margins
Standard value
Intake: 1.0 mm (0.0394 in)
Exhaust: 1.5 mm (0.0590 in)
Service limit
Intake: 0.5 mm (0.0197 in)
2005 Kia Sorento LX
Exhaust: 1.0 mm (0.0394 in)
Fig. 109: Identifying Valve Margins

VALVE SPRING
1. Check the free height of each valve spring and replace if necessary.
2. Using a square, test the squareness of each valve spring. If the spring is excessively out-of-square, replace
it.
Valve spring
Standard value
Free height: 46.4 mm (1.8268 In.)
Load : 24 kg / 37.9 mm (53 lb / 1.492 In.)
Out-of-square: Max. 2°
2005 Kia Sorento LX
Service limit
Free height: 45.4 mm (1.7874 In.)
Out-of-square: Max 4°
2005 Kia Sorento LX
Fig. 110: Checking Valve Springs

RECONDITIONING VALVE SEAT
2005 Kia Sorento LX
1. Before reconditioning, check the valve guide for wear. Replace worn guides if necessary and then
recondition the valve seats.
2. Recondition the valve seat using the Valve Seat Cutter and Pilot.
3. After reconditioning, the valve and valve seat should be lapped lightly with a lapping compound.
REPLACING VALVE GUIDE
1. Using the special tool (09221-3F000(A)), withdraw the old valve guide out the bottom of the cylinder
head.
2. Recondition the valve guide hole so that it can receive the newly press-fitted oversize valve guide.
Fig. 111: Valve Guides Oversize Table

2005 Kia Sorento LX
Fig. 112: Removing & Installing Valve Guides

3. Using the special tool (09221-3F000(A), 09221-3F000(B)) press-fit the valve guide. The valve guide
must be press-fitted from the upper side of the cylinder head. Keep in mind that the intake and exhaust
valve guides are different in length.
4. After the valve guide is press-fitted, insert a new valve and check for proper clearance.
5. After the valve guide is replaced, check that the valve is fully seated. Recondition the valve seats as
necessary.
NOTE: Do not install a valve guide unless it is oversize.
2005 Kia Sorento LX
Fig. 113: Identifying Different Valve Guide Lengths

REPLACING VALVE SEAT RING
1. Cut away the inner face of the valve seat to reduce the wall thickness.
2005 Kia Sorento LX
Fig. 114: Identifying Area To Be Cut Away For Valve Seat Ring Replacement
2. Enlarge the diameter of the valve seat so that it matches the specified hole diameter of the new valve seat
ring.
Fig. 115: Valve Seat Rings Oversize Table

3. Heat the cylinder head to about 250°C (480°F) and press-fit an oversize seat ring for the bore in the
cylinder head.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width
2005 Kia Sorento LX
Intake: 0.9-1.3 mm (0.035-0.051 In.)
Exhaust: 0.9-1.3 mm (0.035-0.051 In.)
REASSEMBLY
1. Install the spring seats.

2. Using special tool (09222-28200), lightly tap the seal in position.
NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage from the
valve guides.
Fig. 116: Using Special Tool, Lightly Tap Valve Seal In Position
3. Apply engine oil to each valve. Insert the valve into their guides. Avoid pushing the valve into the seal by
force. After installing the valve, check that it moves smoothly.
4. Place valve springs so that the side coated with enamel faces toward the valve spring retainer.
2005 Kia Sorento LX
Fig. 117: Place Valve Springs So That Side Coated With Enamel Faces Toward Valve Spring
Retainer
5. Using the special tool (09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve
spring compressor.
NOTE: When the spring is compressed, check that the valve stem seal is not
pressed against the bottom of the retainer.
6. Clean both gasket surfaces of the cylinder head and cylinder block.
7. Verify the identification marks on the cylinder head gasket.
8. Install the gasket so that the surface with the identification mark faces toward the cylinder head.
NOTE: Do not apply sealant to these surfaces.
9. using a torque wrench, tighten the cylinder head bolts in the sequence shown in the illustration.
2005 Kia Sorento LX
Fig. 118: Identifying Cylinder Head Bolt Tightening Sequence

10. Tighten the cylinder head bolts using the torque-angle method. Starting at top center, tighten all cylinder
head bolts in sequence as shown in the illustration, using the 12 mm socket.
Tightening procedure
Cylinder head bolt:
105-115 N.m (1050-1150 kg. cm, 75-82 lb. ft)
TIMING SYSTEM
TIMING BELT
COMPONENTS
CAUTION: Crankshaft pulley bolt is a "one-time" use and must be replaced whenever
it is removed.
2005 Kia Sorento LX
Fig. 119: Identifying Timing System Components & Torque Specifications

REMOVAL
1. Using a 16 mm socket, rotate the tensioner arm clockwise (about 14°) and remove the belt from the
pulley.
2. Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
3. Remove the upper and lower timing belt covers.
4. Remove the auto tensioner.
2005 Kia Sorento LX
Fig. 120: Identifying Auto Tensioner

NOTE: Rotate the crankshaft clockwise and align the timing mark to set the No. 1
cylinder's piston to TDC (compression stroke).
At this time, the timing marks of the camshaft sprocket and cylinder head
cover should coincide with each other.
2005 Kia Sorento LX
Fig. 121: Rotating The Crankshaft Clockwise

5. Unbolt the tensioner to remove the timing belt.
NOTE: If you plan to use the timing belt again, mark the rotation direction on the
belt so you can reinstall it correctly.
INSPECTION
2005 Kia Sorento LX
1. Inspect the belt closely. If the following problems are evident, replace the belt with a new one.
1. Hardened back surface of rubber. Back surface is shiny, non-elastic and so hard that when the nail
of your finger is pressed into it, no mark is produced.
2. Cracked back surface of rubber.
Fig. 122: Examples Of A Bad Timing Belt (1 Of 3)

3. Side of belt is badly worn.
NOTE: A belt in good condition should have clear-cut sides as if it were cut
with a sharp knife.
2005 Kia Sorento LX

4. Teeth are badly worn out.
Initial stage: Canvas on load side of the tooth flank worn (fluffy canvas fibers, rubber gone, color
changed to white, and unclear canvas texture)
Last stage: Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width
reduced).
5. Missing tooth
2005 Kia Sorento LX

2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner
and idler pulley.
2005 Kia Sorento LX
Fig. 125: Inspecting Auto Tensioner

TIMING BELT
2005 Kia Sorento LX
Fig. 126: Identifying Timing Belt At TDC (Installed Position)

INSTALLATION
Install timing belt and auto tensioner using the following procedure.
1. Install idler pulley to idler bracket.

2. Install tensioner arm, shaft and plane washer to cylinder block.
Tightening torque: 35-55 N.m (350-550 kg. cm, 25-40 lb. ft)
2005 Kia Sorento LX
Fig. 127: Installing Tensioner Arm Shaft & Plane Washer

3. Install crankshaft sprocket and align the timing mark.
2005 Kia Sorento LX
Fig. 128: Aligning Crankshaft Gear

CAUTION: Be careful not to bend crankshaft sensing blade.
2005 Kia Sorento LX
Fig. 129: Identifying Crankshaft Sensing Blade

4. Install camshaft sprocket and adjust initial installation state as shown in illustration.
2005 Kia Sorento LX
Fig. 130: Installing Camshaft Sprockets & Adjust To Initial Installation State
5. Install auto tensioner to oil pump case.
NOTE: At this time auto tensioner's set pin should be assembled completely.
2005 Kia Sorento LX
Fig. 131: Install Auto Tensioner Set Pin & Tensioner To Oil Pump Case
6. Align the timing marks of each sprocket and install the timing belt in this order.
1. Crankshaft sprocket
2. Idler pulley
3. Exhaust camshaft sprocket (LH)
4. Intake camshaft sprocket (LH)
5. Water pump pulley
6. Intake camshaft sprocket (RH)
7. Exhaust camshaft sprocket (RH)
8. Tensioner pulley
2005 Kia Sorento LX
Fig. 132: Identifying Timing System Assembled

NOTE: In this step, No. 1 is in TDC (Compression stroke).

Do not insert fingers.
2005 Kia Sorento LX
Fig. 133: Turning Engine Over To Reconfirm Timing Marks

7. After installing the timing belt, reconfirm the timing mark.

8. Install the tensioner pulley.
CAUTION: Crankshaft pulley bolt is a "one-time" use and must be replaced

whenever it is removed.
2005 Kia Sorento LX
9. Install the crankshaft pulley. Tighten crankshaft pulley bolt to specification. See Fig. 119.
10. Pull out the auto tensioner set pin after adjusting timing belt tension. See ADJUSTING TIMING BELT
TENSION.
ADJUSTING TIMING BELT TENSION
ADJUSTMENT WHILE AUTO TENSIONER IS NOT OPERATING AND FIXING PIN BEING KEPT INSTALLED
NOTE: The following procedure is a tension setting (While auto tensioner is not
operating: And fixing pin being kept installed.).
Fig. 134: Adjusting Timing Belt Tension

1. After rotating crankshaft 1/4 revolution reversely, rotate it clockwise to position No. 1 cylinder at TDC.
Then, loosen the center bolt and give the belt 50 kg-cm of tension with tensioner pulley socket (Two pins
are attached) and torque wrench. While maintaining this state, tighten the center bolt to the standard
torque.
Center bolt standard torque:
43 - 55 N.m (430 - 550 kgcm, 31.72 - 40.57 lb. ft.)
2. Pull out the auto tensioner fixing (set) pin.
2005 Kia Sorento LX
Fig. 135: Install Auto Tensioner Set Pin & Tensioner To Oil Pump Case
ADJUSTMENT WITH AUTO TENSIONER OPERATING, AND FIXING PIN IS NOT INSTALLED
NOTE: The following procedure is performed while auto tensioner is operating,

and fixing pin is not installed.
1. After rotating crankshaft 2 revolutions clockwise to position No. 1 cylinder at TDC, wait for about 5
minutes, and measure the amount of protruding of the auto tensioner rod.
CAUTION: This is "leak down" time for the auto tensioner rod to protrude 1mm
when tension caused by rotation of the crankshaft has changed.
2005 Kia Sorento LX
Fig. 136: Checking Projected Length Of Auto Tensioner

2. Check if the amount of rod protruding is in the range of 3.8-4.5 mm (0.15-0.18 in.).
3. Check again if the timing marks of each sprocket is with in specified position.
NOTE: If not within specified position, repeat from step 6 in the method of
installing timing belt and auto tensioner.

Sorento 2005 3.5L

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What are the specifications of the engine components?

What are the specifications of the engine components?

What are the steps to install the timing belt?

What are the steps to install the timing belt?

2005 Kia Sorento LX

2004-06 ENGINES Mechanical - 3.5L V6 - Sorento

Mechanical - 3.5L V6 - Sorento

domingo, 7 de febrero de 2021 08:34:59

Exhaust Max. 0.15 mm (0.0059 in.)

Ring for service 0.25 mm (0.010 in.), 0.50 mm

COOLANT SERVICE STANDARD

Tropical area: 40%

Other area: 50%

Engine coolant : Ethylene glycol base for aluminum radiator

ENGINE COOLANT TEMPERATURE SENSOR SEALANT

Three bond No. 231 or equivalent LOCTITE 962T or equivalent

TIGHTENING TORQUE SPECIFICATIONS

8x22 mm (4) 14-21 (19-28)

(2) Tighten in sequence to specification. See Fig. 1.

(3) Tighten in sequence to specification. See Fig. 2.

Fig. 1: Cylinder Head Bolt Tightening Sequence

Fig. 2: Intake Manifold Nut Tightening Sequence

Fig. 3: Upper Oil Pan Bolt Tightening Sequence

Fig. 4: Cylinder Head Cover Bolt Tightening Sequence

Fig. 5: Lower Oil Pan Bolt Tightening Sequence

SPECIAL SERVICE TOOLS

Fig. 6: Special Service Tools (1 Of 2)

Fig. 7: Special Service Tools (2 Of 2)

Fig. 8: Troubleshooting Symptoms Table (1 Of 2)

Fig. 9: Troubleshooting Symptoms Table (2 Of 2)

CHECKING ENGINE OIL

1. Position a vehicle on a level surface.

NOTE: When refilling, use the proper grade of engine oil.

Fig. 10: Checking Engine Oil Level

SELECTION OF ENGINE OIL

Recommended API classification: SE OR ABOVE [For General]

Recommended API classification: SG OR ABOVE [For North America Europe]

Recommended SAE viscosity grades: See Fig. 11.

Fig. 11: Recommended SAE Viscosity Grades

Satisfy the requirements of the API classification.

CHANGING ENGINE OIL

1. Run the engine until it reaches normal operating temperature.

4. Tighten the drain plug to the specified torque.

Drain and Refill

6. Install the oil filler cap.

REPLACING OIL FILTER

PROCEDURE FOR REPLACING OIL FILTER

1. Use a filter wrench to remove the oil filter.

Oil filter: 11.8-15.7 N.m

(120-160 kg. cm, 8.7-11.6 lb. ft)

CHECKING FOR COOLANT LEAK

1. Loosen the radiator cap.

Fig. 12: Pressure Testing Coolant System For Leaks

Courtesy of KIA MOTORS AMERICA, INC.

4. If there is leakage, repair or replace with the appropriate part.

RADIATOR CAP PRESSURE TEST

1. Use an adapter to attach the cap to the tester.

Main value opening pressure:

Main value closing pressure: